Apparatus for the production of chenille



Dec. 12, 1967 E. MCCARTHY 3,357,166

APPARATUS FOR THE PRODUCTION OF CHENILLE Filed Sept. 20, 1966 4 Sheets-Sheet 1 68 I L 25 n3 |||l||| lllllllll INVENTOR DONAL E. MCCARTHY $54M ATTORNEY Dec. 12, 1967 E. MCCARTHY 3,357,166

APPARATUS FOR THE PRODUCTION OF CHENILLE Filed Sept. 20, 1966 4 Sheets-Sheet 2 DONAL E. Mc CARTHY ATTORNEY Dec. 12, 1967 D. E. M CARTHY 3,357,166

APPARATUS FOR THE PRODUCTION OF CHENILLE Filed Sept. 20, 1966 4 Sheets-Sheet a FIG.

i FIG. 7

H? is us- Bi Bi TNVENTOR j DONAL E. McCARTHY fi wlwy ATTORNEY Dec. 12, 1967 D. E. MCCARTHY APPARATUS FOR THE PRODUCTION OF CHENILLE 4 Sheets-Sheet 4 Filed Sept. 20, 1966 INVENTOR DONAL E. Mc CART HY ATTORNEY United States Patent 3,357,166 APPARATUS FOR THE PRODUCTION OF CHENILLE Donal E. McCarthy, Alexandria, Va., assignor to United Merchants and Manufacturers Inc. New York, N.Y., a

corporation of Delaware Filed Sept. 20, 1966, Ser. No. 580,631 10 Claims. (CI. 57-24) The present invention relates, in general, to a novel apparatus for the formation of chenille yarn and, in particular, to an improved, efiicient structure for the production of chenille in increased productivity and quality.

Chenille is a product made of a plurality of wisps of fibrous material constituting what may be termed the weft of the chenille, each of the wisps thereof being held between the convolutions or twists of a pair of threads or strands of twisted fibrous material constituting what may be termed the warp of the chenille serving as a foundation or holding medium for the cross or transverse fibrous strands of the chenille weft.

In prior apparatus employed in the production of chenille, it has been customary to employ a plurality of cops for feeding therefrom threads or groups of threads which are to form the weft strands of the chenille and to direct the threads through suitable guide means to a hollow forming member upon which the threads are helically wound. The plurality of cops generally is supported by a driven rotating plate and the threads or groups of threads ordinarily are fed to the stationary forming mandrel upon which the threads are mounted. As can be readily appreciated, the mounting of a plurality of independently rotating cops on a positively driven rotary plate or ring can set up undesirable vibrational forces acting on the supporting mechanism for the units, particularly if the cops are uneven in balance due to their respective weights which is determined by the amount of threads carried thereby, and also by reason of the cops not being arranged in a true circle about the periphery of the rotary plate or ring on which they are rotatably mounted. Obviously, upon high speed rotation of a plate or ring carrying such unevenly weighted cops or cops improperly arranged on the periphery of the plate or ring, vibration forces are created due to the unevenness of rotation of the unit and these forces are transmitted to the supporting surface for the units. These vibrational forces are most undesirable since a supporting surface usually has thereon a plurality of the aforementioned units and the vibrational forces created thereby are oftentimes of such intensity as to call for a momentary shutdown of the operation of the units on the supporting surface so as to correct this situation either by the replacement of some of the cops or by rearranging the same on the periphery of the rotary plate or ring on which they are mounted so as to eliminate these vibrational forces which could, if permitted to continue, cause irreparable damage to the units. Of course, to correct for vibrational forces imparted to the supporting surface of the units mounted thereon necessitates the shutdown of all of. the units on the support and this loss ofoperating time is one which is to be avoided if the units are to operate at top efficiency and to be able to produce as much chenille threads within a given period of time as they are capable of producing.

Also, it will be appreciated that formation of the helix of weft threads on a stationary mandrel poses somewhat. of a problem in removing the helix, as formed, from the mandrel wthout damage to the weft threads. Also, in such instances somewhat elaborate means have to be re sorted toin order to cut the weft threads upon incipient formation of the chenille yarn product.

In this invention the need for a plurality of cops is 3,357,166 Patented Dec. 12, 1967 eliminated by providing a single weft thread-carrying spindle for accomplishing the same result. Such provision minimizes the vibrational forces imparted to the framework of the apparatus and the supporting surface having thereon a plurality of units employed in the making of chenille yarn. Also, in this invention the Weft-carrying spindle is mounted Within a rotating housing which ex. tends completely over and around the surface area of the thread-carrying spindle 'so as to contain or restrict the outward travel of the thread or group of threads to within the confines of said housing as the threads are being unwound therefrom, thereby minimizing any ballooning effects of the unwound threads occasioned by the centrifugal forces which tend to balloon such unwinding threads. In a weft thread-carrying spindle of the type employed in the present apparatus, it is not uncommon for the spindle and housing to be driven at speeds upwards of 2,000 rpm. Therefore, it will be readily apparent that threads or groups of threads being unwound from such a highly rotating spindle will tend to balloon due to the centrifugal forces imposed thereon. This is very objectionable since it increases the risks of breakage of the threads or groups of threads being unwound from the spindle with ultimate increase of shutdown time of operation of the machine so as to permit for the repair or replacement of the broken threads. The structure of the present invention eliminates such ballooning of the threads, thereby minimizing the amount of shutdown time of the machine due to the repair of replacement of the broken threads occasioned by such ballooning thereof.

In this invention, the problems inherent in the use of a stationary mandrel are overcome by providing a traveling forming device upon which the weft thread helix is wound, which forming device is separable lengthwise to permit easier cutting of the weft thread helix. This forming device comprises a continuous composite tape adapted to pass axially through the spindle. Also, in the present invention a brake and guide ring is provided for the threads or group of threads being unwound from the fastrotating weft thread-carrying cone-shaped spindle. Such ring is located in close proximity to the outlet end of the rotating housing so as to impede or arrest the outward travel of such unwinding threads from within said housing and to direct the same onto the traveling forming device.

Means are provided in this invention to carry a foundation warp thread along each side of the continuous movingcomposite tape, to cut the weft thread, to binder war thread to each side of the helical twist the foundation and binder warp threads with the cut weft threads held between the warp threads, producing simultaneously two lengths of identical chenille yarn. The cutting means may be of a rotating or oscillating type.

The composite moving tape mandrel element is composed of two endless tapes which are together in face-tosupply a weft and together,

face relationship at the weft-winding station and which separate at the cutting station. Each of the endless tapes comprises a suitable length of, preferably metal, band with the ends of each band joined together by a readily broken flat joint. The endless tapes can be provided in a variation of widths so that for any variation in the widths of the elements there will be a variation in the apparent diameter defined by the chenille yarn products.

The invention will be better understood by reference to the accompanying drawings, which are to be considered illustrative only and not limiting, and in which:

FIGURE 1 is a front elevational view of a pair of chenille yarn fabricating machines embodying the present invention.

FIGURE 2 is a partially enlarged fragmentary side elevational view of one of the devices of FIGURE 1.

FIGURE 3 is a partially enlarged front elevational view of one of the devices described in FIGURE 1 with parts broken away.

FIGURE 4 is a still further enlarged detailed fragmentary sectional view as viewed along the lines 4 4 of FIGURE 2.

FIGURE 5 is an enlarged detailed fragmentary sectional view taken along the line 5-5 of FIGURE 4.

FIGURE 6 is a transverse detailed sectional view taken along the line 66 of FIGURE 4.

FIGURE 7 is an enlarged fragmentary explodable elevational view of the detachable bands.

FIGURE 7A is a view similar to FIGURE 7 showing one of the bands as being attached.

FIGURE 8 is an enlarged detailed fragmentary view partially in cross section taken along the line 8-8 of FIGURE 3 showing the chenille cutting operation.

FIGURE 9 is an enlarged detailed fragmentary transverse sectional view taken along the line 99 of FIG- URE 8.

FIGURE 10 is a perspective view showing the cutting operation mentioned in FIGURE 8.

As an introduction to the apparatus it may be well to consider first FIGURE 10. In this figure, weft thread 11 is being applied in the form of a helix 13 to the composite tape portion 15 formed by the face-to-face meeting of the two endless bands 18 and 20 which are moving in the direction of the arrow in FIGURE 10. Each side of this composite tape element carries a foundation warp thread 22, 24 around which the weft helix 13 is wound. Binder warp threads 25 and 28 are supplied to the helix 13 .by passage around the rollers 30 and 33 respectively. In the downward passage of the helix 13, just after the association of the binder warp threads 25 and 28 on the outside of the helix 13 is completed, the helix is cut lengthwise by the cutting means 36 and the foundation and binder warp threads are twisted around each other to produce the chenille product yarns 39 and 42.

The chenille-ytam-manufacturing apparatus of this invention includes a number of conventional features which are shown in the drawings only insofar as necessary to permit proper explanation of the invention. Such conventional parts include a framework 44 and one or more motors (not shown) to supply power to the operating units of the mechanism, for example, by one or more drive shafts (not shown) which operate drive belts such as 48, drive shafts such as 50 and oscillating shafts 52 and 55. Spools, such as 58, 60 and 63 are provided to supply the foundation warp threads 22 and 24 and the binder warp threads 25 and 28. These threads, as well as the weft thread 11, may be single threads or, if desired, they may comprise a plurality of single threads wound one on the other so as to present what may be termed a reinforced thread comprising a plurality of such single threads. The weft thread 11 usually will supply 2, 4, etc., ends simultaneously for helical winding. The warp threads may be trained over suitable spring-type thread guides 66, 67, 68, 69 and/or roller-type guides 70 and 72 which are journalled for rotation in any conventional manner.

In this invention a rotating housing 75, which is cylindrical in form is suitably supported from the framework 44, as for example by the support ring 78 and hollow tube 80. Hollow tube 80 bears on its outside the com posite pulley 82 which has varying diameters to provide variations in speed of rotation of the cylindrical housing 75, depending upon which section of the pulley 82 is engaged with the drive belt 48.

As can be seen, the hollow tube 80 extends into and through the cylindrical housing 75 coaxially therewith. Advantageously the tube 80 is formed integrally with the housing 75 being rigidly joined thereto at 84. As can be readily seen, a supply 88 of weft thread, from which the thread 11 is drawn, is wound upon the tube 80 in a moreor-less conical fashion and composite tape portion 15 passes through the center of hollow tube 80. The cylindrical housing 75 confines the unwinding thread or threads 11 therein during the unwinding operation and can be constructed of any material found suitable for such a structure. However, it is important that the interior surface of the housing be of extremely smooth finish so as to minimize the rupture of threads coming in contact therewith during the unwinding operation of threads housed therein.

Housing 75 is closed at one end as shown at 90 in the drawing and may comprise a double wall construction so as to impart rigidity thereto. As mentioned, the hollow tube 80 passes through the housing 75 and projects from the open end 93 thereof. This trailing end of the tube 80 is surnounded by the guide and brake ring 96, which is secured in any manner to a suitable bracket 99 on the support 44. The ring 96 is positioned in close proximity to the open end 93 of the housing 75 and is preferably formed of a highly polished steel or other polished material. It should be pointed out that the ring 96 is to be constructed of such a material as will withstand wear of the strands of threads passing therethrough.

The ring 96 is mounted for adjustment in the bracket 99 and a set screw 101 or the like can be provided for firmly maintaining the ring in an adjusted position. Ring 96 is capable of adjustment with respect to the outlet end 93 of the housing 75, since, in some instances, it may be desirable to adjust the angle of disposition of such ring with respect to the outlet end of the housing 75 so as to insure for the proper and orderly deposit of the weft threads 11 traveling therethrough in the form of the helix 13 on the moving composite tape portion 15. As pointed out, the helix 13 surrounds the foundation warp threads 22 and 24 and the width of the helix will determine the apparent diameter of the chenille yarn product, this width being, in turn, determined by the width of the composite tape portion 15.

As pointed out, this composite tape portion 15 is composed of the face-to-face conjunction of the endless? bands 18 and 20. These bands are driven by the conveyor drums 103 and 105 respectively, and these drums may be rotated-103 clockwise in the view of FIGURE 1 and 105 counter-clockwise-by any suitable means such as the composite pulley 107 and suitable gearing 109, the motive power being ultimately obtained from the motor, as aforesaid.

Two return Wheels 111 and 113 are provided at a portion of the mechanism opposite the helix-forming station from the drums 103 and 105. The endless tapes 18 and 20 are held by return rollers 111 and 113 in a suitably taut condition and to this end the rollers 111 and 113 may be provided with spring biasing, clutch or other mechanisms, not shown. Although-these tapes are endless during formation of the chenille yarn, in actuality they are bands held together at their ends by a flat joint such as is illustrated in FIGURES 7 and 7A. While any suitable flat joint may be employed, the one illustrated is preferred. This joint is made by providing a T-shaped notch 115 in one end 117 of the tape and a T-shaped 'projection 119 in the other end 121 of the same tape. Such a joint will serve to make each of the bands 18 and 20 endless, provided the proper tension is kept on the tapes by means of the rollers 111 and 113 or other auxiliary rollers, if desired. Thus the ends of the tapes can be disconnected and the apparatus assembled by passing the free ends through the hollow tube 80 and joining the ends after such passage. The face-to-face meeting of the tapes to form the composite section 15 can be assured by providing any suitable means, for example the upper rollers 123 and 125 over which the tapes 18 and 20, respectively, pass. Joining of the tapes to maintain close face-to-face juxtaposition is assured at the bottom of the composite section 15 by the rollers 30 and 33 over which pass the binder warp threads 25 and 28. Separation of the tapes 18 and 20 is assured by providing a distance between the lower rollers 111 and 113. Separation of the tapes 18 and 20 at the lower end of the composite portion 15 produces a tension in the helix 13 which increases the effectiveness of cutting means 36.

As mentioned, this cutting means may be of the rotary type, but preferably comprises a holder 128 for a removable blade 130, the holder and blade being drawn back and forth against the bottom of the helix 13 by the oscillating shaft 50. The blowing mechanism 133 may be provided to remove any lint produced in cutting the helix of weft thread. Such mechanism may consist of the cylinder 135 having an opening 137 directed toward the cutting station. The piston 140 oscillates in this cylinder due to the shaft 55, alternately drawing air into the cylinder and forcing out a blast of air toward the cutting section.

Twisting of the foundation and binder warp threads is readily accomplished by any conventional means, for example, the ring-twisting mechanism illustrated which serves to convert the rotation of take-up spindles into torque on the chenille yarn product. These take-up spindles 144 and 148 receive the product yarns 39 and 42 respectively and are rotatably mounted on a supporting platform 150. These spindles 144 and 148 rotate at a suitable speed, due, for example to transmission belt 153. Also, a relative reciprocating motion between the spindles 144 and 148 and the feed eyes 155 and 157 is established due to cam 160 fastened to the cam shaft 163. It will be noted that yarn guides 166 and 168 provide for each yarn strand leaving the cutting station to be held more-or-less coaxially with its respective spindle 144 or 148.

It will be noted from FIGURE 1 that two or more chenille-yarn making units can be placed on the same framework, each unit being completely autonomous with respect to other adjoining groups. Also, the units need not be vertically oriented, as shown, but may be horizontally or slopingly placed or may provide a direction of travel for the yarn product different from the direction of travel of the composite tape.

To summarize, therefore, this invention employs a single spindle to deliver weft thread or thread groups, thereby eliminating completely any imbalance in the rotating structure and thereby also eliminating any vibrational forces imparted by such imbalance, resulting in increased stability of the units on a supporting surface to operate more smoothly at all times and with less resultant amount of shutdown of the units for servicing or repair thereof, due to such unbalance, all of which add to the operating efliciency of the units. Also, this invention supplies a moving form on which the weft-thread is wound, thereby further providing for smoother operation of the apparatus. Also, by placing the single weft supply within the confines of a rotating member which extends completely around the supply, the threads which are unwound therefrom are prevented from ballooning outwardly, thereby minimizing the breakage 'of threads due to such ballooning. The guide and brake ring serves a dual function, one being that of retarding the forward travel of the unwinding threads from the cop and, secondly, it directs such thread or threads onto the moving form.

What is claimed is:

1. An apparatus for the production of chenille yarn comprising a hollow rotary spindle, a cone-shaped supply of weft thread mounted on said spindle, a housing having an open and a closed end extending over said supply for confining weft threads therein as they are unwound from said supply, a brake and guide ring mounted in close proximity to the open end of said housing for limiting the outward travel of said unwinding threads and for directing the same to a forming member which is moving from the said closed end to the said open end, said member comprising a composite tape section formed by the face-to-face juxtaposition of two endless tapes, said composite tape section passing through the said hollow rotary spindle.

2. The structure recited in claim 1 wherein said brake and guide ring is adjustably mounted with respect to said housing.

3. The structure recited in claim 1 wherein said brake and guide ring extends over and surrounds the said moving forming member.

4. The structure recited in claim 1 wherein said housing comprises a rotating cylindrical member extending coaxially with said spindle.

5. The structure of claim 1 in which the said unwinding weft threads compose a helix on said moving form.

6. The structure recited in claim 5 having means for placing on opposite sides of said composite tape section, before its passage through said spindle, a foundation warp thread and having means for placing on opposite sides of said weft-thread helix a binder warp thread.

7. The structure of claim 6 in which means are provided to split said composite tape section lengthwise immediately after its travel past said means for placing said binder warp thread and means are provided between the resulting split tape to out said weft-thread helix.

8. The structure of claim '7 in which means are provided to twist together each binder warp thread with its corresponding foundation warp thread to produce two strands of chenille yarn.

9. The structure of claim 7 in which means to split the composite tape comprises a pair of spaced-apart rollers adapted to keep said endless tapes taut.

10. The structure of claim 1 in which each endless tape is a band having its ends fastened to each other by means of a flat joint.

References Cited UNITED STATES PATENTS 1,687,942 10/1928 Kriegl 5724 1,927,292 9/ 1933 Neif et al. 57-24 2,491,292 12/ 1949 Wilmsen 57-24 2,551,986 5/1951 Weller 5724 2,684,565 7/1954 Hortal 57-24 FOREIGN PATENTS 997,235 1/1952 France. 1,031,021 6/1953 France. 1,276,098 10/ 1961 France.

123,653 6/1958 Russia.

FRANK I. COHEN, Primary Examiner. D. WATKINS, Assistant Examiner. 

1. AN APPARATUS FOR THE PRODUCING OF CHENILLE YARN COMPRISING A HOLLOW ROTARY SPINDLE, CONE-SHAPED SUPPLY OF WEFT THREAD MOUNTED ON SAID SPINDLE, A HOUSING HAVING AN OPEN AND A CLOSED END EXTENDING OVER SAID SUPPLY FOR CONFINING WEFT THREADS THEREIN AS THEY ARE UNWOUND FROM SAID SUPPLY, A BRAKE AND GUIDE RING MOUNTED IN CLOSE PROXIMITY TO THE OPEN END OF SAID HOUSING FOR LIMITING THE OUTWARD TRAVEL OF SAID UNWINDING THREADS AND FOR DIRECTING THE SAME TO A FORMING MEMBER WHICH IS MOVING FROM THE SAID CLOSED END TO THE SAID OPEN END, SAID MEMBER COMPRISING A COMPOSITE TAPE SECTION FORMED BY THE FACE-TO-FACE JUXTAPOSITION OF TWO ENDLESS TAPES, SAID COMPOSITE TAPE SECTION PASSING THROUGH THE SAID HOLLOW ROTARY SPINDLE. 